2009 YAMAHA WR 450F clutch

5-34
OIL FILTER ELEMENT AND WATER PUMP
OIL FILTER ELEMENT AND WATER PUMP
REMOVING THE OIL FILTER ELEMENT AND WATER PUMP
Order Part name Q'ty Remarks
Right engine guard Refer to "ENGINE REMOVAL" section.
Drain the engine oil. Refer to "CHANGING THE ENGINE OIL"
section in the CHAPTER 3.
Drain the coolant. Refer to "CHANGING THE COOLANT" sec-
tion.
Exhaust pipe Refer to "EXHAUST PIPE AND SILENCER"
section.
Brake pedal Refer to "ENGINE REMOVAL" section.
Clutch cover Refer to "CLUTCH" section.
1 Oil filter element cover 1
2 Oil filter element 1
3 Coolant pipe 2 1
4 Water pump housing 1
5Pin 2
6 Oil tank breather hose 1
7 Kickstarter crank 1
8 Right crankcase cover 1
10 Nm (1.0 m kg, 7.2 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb)
33 Nm (3.3 m kg, 24 ft lb)
14 Nm (1.4 m kg, 10 ft lb)
12 Nm (1.2 m kg, 8.7 ft lb)

5-38
BALANCER
BALANCER
REMOVING THE BALANCER
Order Part name Q'ty Remarks
Primary driven gear Refer to "CLUTCH" section.
Right crankcase cover Refer to "OIL FILTER ELEMENT AND WA-
TER PUMP" section.
Stator Refer to "CDI MAGNETO" section.
1 Nut (balancer) 1 Refer to removal section.
2 Nut (primary drive gear) 1 Refer to removal section.
3 Nut (balancer shaft driven gear) 1 Refer to removal section.
4 Lock washer 1
5 Balancer 1
6 Straight key 1
7 Conical washer 1
8 Primary drive gear 1
9 Balancer shaft drive gear 1
10 Lock washer 1
11 Balancer shaft driven gear 1

5-40
OIL PUMP
OIL PUMP
REMOVING THE OIL PUMP
Order Part name Q'ty Remarks
Primary driven gear Refer to "CLUTCH" section.
Right crankcase coverRefer to "OIL FILTER ELEMENT AND WA-
TER PUMP" section.
1 Circlip 1
2 Washer 1
3 Oil pump drive gear 1
4 Oil pump assembly 1
5 Dowel pin 2
6 Outer rotor 2 1
7 Circlip 1
8 Inner rotor 2 1
9 Dowel pin 1
10 Oil pump cover 1
11 Outer rotor 1 1
12 Inner rotor 1 1
13 Dowel pin 1
14 Washer 1

5-46
KICK SHAFT AND SHIFT SHAFT
INSTALLING THE SHIFT GUIDE
AND SHIFT LEVER ASSEMBLY
1. Install:
• Spring "1"
• Pawl pin "2"
•Pawl "3"
To shift lever "4".
Apply the engine oil on the spring,
pawl pin and pawl.
2. Install:
• Shift lever assembly "1"
To shift guide "2".
3. Install:
• Shift lever assembly "1"
• Shift guide "2"
• The shift lever assembly is installed
at the same time as the shift guide.
• Apply the engine oil on the bolt
(segment) shaft.
4. Install:
• Bolt (shift guide) "1" INSTALLING THE SHIFT SHAFT
1. Install:
• Roller "1"
• Collar "2"
• Torsion spring "3"
• Washer "4"
• Shift shaft "5"
Apply the engine oil on the roller and
shift shaft.
2. Install:
• Shift pedal
Refer to "AC MAGNETO AND
STARTER CLUTCH" section.
INSTALLING THE KICK SHAFT
ASSEMBLY
1. Install:
• Kick gear "1"
• Washer "2"
• Circlip "3"
• Ratchet wheel "4"
• Spring "5"
• Washer "6"
• Circlip "7"
To kick shaft "8".
• Apply the molybdenum disulfide oil
on the inner circumferences of the
kick gear and ratchet wheel.
• Align the punch mark "a" on the
ratchet wheel with the punch mark
"b" on the kick shaft.
2. Install:
• Torsion spring "1"
To kick shaft "2".
Make sure the stopper "a" of the tor-
sion spring fits into the hole "b" on the
kick shaft.
3. Install:
• Spring guide "1"
Slide the spring guide into the kick
shaft, make sure the groove "a" in the
spring guide fits on the stopper of the
torsion spring.
4. Install:
• Kick shaft assembly "1"
• Washer "2"
• Apply the molybdenum disulfide
grease on the contacting surfaces
of the kick shaft stopper "a" and kick
shaft ratchet wheel guide "3".
• Apply the engine oil on the kick
shaft.
• Slide the kick shaft assembly into
the crankcase and make sure the
kick shaft stopper "a" fits into the
kick shaft ratchet wheel guide.
5. Hook:
• Torsion spring "1"
Turn the torsion spring clockwise and
hook into the proper hole "a" in the
crankcase.
INSTALLING THE KICK IDLE GEAR1. Install: Bolt (shift guide):
10 Nm (1.0 m•kg, 7.2
ft•lb)

5-48
AC MAGNETO AND STARTER CLUTCH
AC MAGNETO AND STARTER CLUTCH
REMOVING THE AC MAGNETO AND STARTER CLUTCH
Order Part name Q'ty Remarks
Drain the engine oil.Refer to "CHANGING THE ENGINE OIL"
section in the CHAPTER 3.
Seat and fuel tankRefer to "REMOVING THE SEAT, FUEL
TANK AND SIDE COVERS" section in the
CHAPTER 3.
Disconnect the AC magneto lead.
1 Shift pedal 1
2 Cover (torque limiter) 1
3 Torque limiter 1 Do not disassemble.
4 Crankcase cover (left) 1
5 Gasket 1
6 Dowel pin 2
7 Idle gear 1
8 Bearing 1
9Shaft 1
10* Nut (rotor) 1 Refer to NOTE.
11 Rotor 1 Refer to removal section.

5-49
AC MAGNETO AND STARTER CLUTCH
Tighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb), loosen and retighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb).
12 Woodruff key 1
13 Starter clutch assembly cover 1 Refer to removal section.
14 Starter clutch 1 Refer to removal section.
15 Starter clutch drive gear 1
16 Holder 1
17 Pickup coil 1
18 Stator 1 Order Part name Q'ty Remarks

5-50
AC MAGNETO AND STARTER CLUTCH
REMOVING THE ROTOR
1. Remove:
• Nut (rotor) "1"
• Washer
Use the sheave holder "2".
2. Remove:
• Rotor "1"
Use the rotor puller "2".
REMOVING THE STARTER
CLUTCH
1. Remove:
• Starter clutch assembly cover "1"
Insert a thin screwdriver or the like
under the convexity "a" and remove
the starter clutch assembly cover by
prying it gently to void damage to the
cover.
2. Remove:
• Starter clutch "1"
Using a thin screwdriver or the like,
remove the plate "a" while prying it
upward little by little.
CHECKING THE AC MAGNETO
1. Inspect:
• Rotor inner surface "a"
• Stator outer surface "b"
Damage→Inspect the crankshaft
runout and crankshaft bearing.
If necessary, replace AC magneto
and/or stator.
CHECKING THE WOODRUFF KEY
1. Inspect:
• Woodruff key "1"
Damage→Replace.
CHECKING THE STARTER
CLUTCH
1. Check:
• Starter clutch
Damage/wear→Replace.
2. Check:
• Idle gear
• Idle gear shaft
• Starter clutch drive gear
Pitting/burrs/chips/roughness/
wear→Replace the defective
parts.3. Check:
• Starter clutch operation
a. Install the starter clutch drive gear
"1" onto the starter clutch "2" and
hold the starter clutch.
b. When turning the starter clutch
drive gear counterclockwise "B",
the starter clutch and the starter
clutch drive gear should engage.
If the starter clutch drive gear and
starter clutch do not engage, the
starter clutch is faulty and must be
replaced.
c. When turning the starter clutch
drive gear clockwise "A", it should
turn freely. If the starter clutch
drive gear does not turn freely, the
starter clutch is faulty and must be
replaced.
CHECKING THE TORQUE LIMITER
1. Check:
• Torque limiter
Damage/wear→Replace.
INSTALLING THE AC MAGNETO
AND STARTER CLUTCH
1. Install:
• Stator "1"
• Bolt (stator) "2"
• Pickup coil "3"
• Holder "4"
• Bolt (pickup coil) "5" Sheave holder:
YS-1880-A/90890-
01701
Rotor puller:
YM-04142/90890-04142
Bolt (stator):
7 Nm (0.7 m•kg, 5.1
ft•lb)
Bolt (pickup coil):
10 Nm (1.0 m•kg, 7.2
ft•lb)

5-51
AC MAGNETO AND STARTER CLUTCH
• Pass the AC magneto lead "5" un-
der the pickup coil.
• Pass the AC magneto lead "4" un-
der the holder as shown.
• Take care not to catch the AC mag-
neto lead between crankcase cover
ribs.
• Tighten the bolt (stator) using the
T25 bit.
• Apply the sealant to the grommet of
the AC magneto lead.
2. Install:
• Starter clutch drive gear "1"
Apply the engine oil on the starter
clutch drive gear inner circumference.
3. Install:
• Starter clutch "1"
To rotor "2".
• Install the starter clutch with its
plate side upward.
• While installing the starter clutch,
push in the projections "a" one by
one on the clutch circumference.
• Push in the starter clutch until it hits
the rotor.
4. Install:
• Starter clutch assembly cover "1"
To rotor "2".
Install the starter clutch assembly
cover by fitting its pawls "a" into the
groove "b" in the rotor.
5. Install:
• Woodruff key "1"
• Rotor "2"
• Degrease the contact surfaces of
the tapered portions of the crank-
shaft and rotor.
• When installing the woodruff key,
make sure that its flat surface "a" is
in parallel with the crankshaft center
line "b".
• When installing the rotor, align the
keyway "c" of the rotor with the
woodruff key.
6. Install:
• Washer (rotor)
• Nut (rotor) "1"
Use the sheave holder "2"
Tighten the rotor nut to 65 Nm (6.5
m•kg, 47 ft•lb), loosen and retighten
the rotor nut to 65 Nm (6.5 m•kg, 47
ft•lb).
7. Install:
• Shaft "1"
• Bearing "2"
• Idle gear 2 "3"
Apply the engine oil on the shaft,
bearing and idle gear inner circumfer-
ence.
8. Install:
• Dowel pin
• Gasket [crankcase cover (left)]
• Crankcase cover (left) "1"
• Bolt [crankcase cover (left)]
Tighten the bolts in stage, using a
crisscross pattern.
9. Install:
• Washer "1"
• Torque limiter "2"
• Washer "3"
Apply the engine oil to the shaft and
washers.
YAMAHA Bond No. 1215
(ThreeBond® No. 1215):
90890-85505
Nut (rotor):
65 Nm (6.5 m•kg, 47
ft•lb)
Sheave holder:
YS-1880-A/90890-
01701
Bolt [crankcase cover
(left)]:
10 Nm (1.0 m•kg, 7.2
ft•lb)